Low Cost Additive Manufacturing for Cast Tooling
Award last edited on: 9/19/2022

Sponsored Program
Awarding Agency
Total Award Amount
Award Phase
Solicitation Topic Code
Principal Investigator
Dan Z Sokol

Company Information

Renaissance Services Inc

1825 Corporate Center Boulevard
Springfield, OH 45324
   (937) 322-3227
Location: Single
Congr. District: 10
County: Green

Phase I

Contract Number: FA8650-19-P-5164
Start Date: 6/12/2019    Completed: 6/12/2020
Phase I year
Phase I Amount
Ever-changing threats mean that production quantities for some new Air Force systems may be limited as missions-and accompanying system designs-change with increasing frequency. This means production runs of no more than 200-250 units, particularly for expendable and attritable aircraft that depend on small engines. For these engines, a critical factor is tooling required to produce limited numbers of essential components, including investment castings. The Low Cost Additive Manufacturing for Cast Tooling program offers rapid low-cost wax injection dies for limited casting quantities required by these engines. The program will establish a solution that does not require substantive changes in the investment casting processes at the foundries or changes in engine component design processes at small engine OEMs. It will recognize, evaluate, and demonstrate low cost, limited life 3D-printed wax pattern injection dies that encompass a range from simple to complex and capture cost benefits and other advantages associated with the approach. A team, led by Renaissance Services, and comprised of foundries and turbine engine designers, will perform the program. Ultimately, the effort will demonstrate up to 80% cost improvement over conventional hard tooling for limited quantity systems, accompanied by comparable reductions in lead times for wax die injection tooling.

Phase II

Contract Number: FA8650-22-C-5009
Start Date: 3/10/2022    Completed: 6/20/2023
Phase II year
Phase II Amount
Small and medium engines for Air Force expendable and attritable systems demand component parts that can be delivered rapidly, affordably, and in small quantities. For these systems it can mean an entire production run of no more than 200-250 units. A critical factor is the tooling required to produce limited numbers of essential components, including investment castings. The Phase I ALLTEC program demonstrated the feasibility of applying additive manufacturing technologies to affordably produce tooling and castings with the potential to meet the requirements of limited quantity, rapidly evolving engines for expendable and attritable systems. The purpose of the Phase II effort is to further build on and expand this demonstrated feasibility to enable longer-term production application and commercialization of these proven technologies and production capabilities.